This application is directed to polymer blends of polyethylene naphthalate, polytrimethylene terephthalate, and polyethylene naphthalate, for use in fibers, such as carpet fibers, and other applications. This application is also directed to methods of producing such polymer blends and fibers.

Recycling devices for producing additive manufacturing filament from received materials including objects to be recycled, discarded objects, obsolete objects, and the like. A recycling device may include a material processing system an extrusion mechanism and a spooling assembly. The material processing system receives material, reduces the size of the received material via a material size reducer and actively pushes the material through at least a portion of the device. The extrusion mechanism produces filament from the material and the spooling assembly loads the filament onto a spool for later use. The spooling assembly may include detachable elements configured to interface with and supply filament to an additive manufacturing device. Depending on configuration, recycling devices may create filament from plastic, metal, in-situ material, or a combination thereof.

A method of manufacturing bulked continuous carpet filament, in various embodiments, comprises: (A) providing an expanded surface area extruder; (B) providing a spinning machine having an inlet that is operatively coupled to an expanded surface area extruder outlet; (C) using a pressure regulation system to reduce the pressure within the expanded surface area extruder; (D) passing a plurality of flakes comprising recycled PET through the expanded surface area extruder to at least partially melt the plurality of flakes to form a polymer melt; and (E) substantially immediately after passing the plurality of flakes through the expanded surface area extruder, using the spinning machine to form the polymer melt into bulked continuous carpet filament. In some embodiments, the method may include passing the plurality of flakes comprising recycled PET through a PET crystallizer prior to extrusion.

A method of manufacturing bulked continuous carpet filament which, in various embodiments, comprises: (A) washing a plurality of flakes of recycled PET; (B) providing a PET crystallizer; (C) after the step of washing the plurality of flakes, passing the plurality of flakes of recycled PET through the PET crystallizer; (D) at least partially melting the plurality of flakes into a polymer melt; (E) providing a multi-rotating screw (MRS) extruder having an MRS section; and a vacuum pump in communication with the MRS section; (F) using the vacuum pump to reduce a pressure within the MRS Section; (G) after the step of passing the plurality of flakes through the PET crystallizer, passing the polymer melt through the MRS Section; and (H) after the step of passing the polymer melt through the MRS extruder, forming the polymer melt into bulked continuous carpet filament.

Method for recycling scrap that contains one or more heat resistant fibers and from 25 to 60 wt. %, based on the total weight of the scrap, of an at least partially uncured to fully uncured two component thermosetting resin mixture of (i) one or more thermosetting resins, and (ii) a solid hardener, the methods comprising shredding the scrap to an average size of from 3 to 50 mm, mixing the shredded scrap, preferably after preheating the scrap, to provide a fluid material charge and then compression molding the fluid material charge to make a cured composite material.

This disclosure relates to a method of utilising waste products in manufacturing. It is particularly suited to manufacturing composite products for applications including, but not limited to, structural, thermal insulation, acoustic insulation and related applications and is described in relation to manufacture in small scale environments but it will be clear that the method and products have broad applications.

A method of making polymeric composite particles from polymeric scrap material, virgin polymeric material, or mixtures thereof and glass particles by subjecting a mixture of the polymeric particles and glass particles to a solid state shear pulverization and in-situ polymer compatibilization.

A method utilizes waste product in manufacturing, such as manufacture of filaments or micro-pellets for use in manufacturing applications such as additive manufacturing, extrusion, injection molding, blow molding and other applications.

A cellulose fiber dispersion polyethylene resin composite material formed by dispersing a cellulose fiber into a polyethylene resin, in which a proportion of the above-described cellulose fiber is 1 part by mass or more and 70 parts by mass or less in a total content of 100 parts by mass of the polyethylene resin and the cellulose fiber, and the polyethylene resin satisfies a relationship: 1.7>half-width (Log(MH/ML))>1.0 in a molecular weight pattern obtained by gel permeation chromatography measurement, and a formed body and a pellet using the same, a production method therefor, and a recycling method for the cellulose fiber adhesion polyethylene thin film piece.

A process for the production of fiber-reinforced components or semifinished products is provided, where fibers are saturated with monomer. The process includes at least one of adding flakes including fibers and adding individual fibers. For this, the fibers, the monomer, and the flakes including fibers and/or the individual fibers are added to an injection-molding machine and forced into an injection mold, whereupon polymerization of the monomer is completed in the injection mold. Alternatively a fiber structure on a conveyor belt is saturated with a solution including a monomer, optionally including an activator, and optionally including a catalyst. In a following step, individual fibers and/or flakes including fibers are distributed on the saturated fiber structure, the fiber structure is passed through a roll pair in which pressure is exerted onto the fiber structure, and finally the saturated fiber structure is cooled so that the monomer solidifies.